Systems and methods for processing of coverings such as leather hides and fabrics for furniture and other products

ABSTRACT

Methods and systems for processing coverings such as leather hides and fabrics are provided. A system can include a worktable having a surface on which a covering is placeable. An imaging device can be positionable relative to the worktable. The imaging device can be configured to obtain an image of the covering on the surface of the worktable. A projector can be positionable relative to worktable. The projector can be configured to project an image onto the surface of the worktable and the covering on the surface of the worktable. A controller can be in communication with the imaging device and projector. The controller can be configured to correct images taken by the imaging device. The controller can also be configured to correct the images projected onto the surface of the worktable and the covering thereon. The controller can be configured to permit the showing of virtual markings on the covering placed on the surface of the worktable through an image projected thereon by the projector. The covering can then be marked or cut along the virtual markings.

RELATED APPLICATIONS

This application is a continuation patent application which claims thebenefit of the filing date of U.S. patent application Ser. No.12/780,646, filed May 14, 2010, the disclosure of which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

The present subject matter relates to systems and methods for theprocessing of coverings, such as leather hides and fabrics. Inparticular, the present subject matter relates to systems and methodsthat can be used to efficiently optimize leather and fabric yield foruse in manufacturing of consumer products, such as furniture.

BACKGROUND

Both leather animal hides and fabrics are used throughout the worldtoday in the construction of consumer products. For example, leather andfabrics are popular coverings used in furniture and other consumerproducts. In today's economy, for furniture manufacturing to beprofitable, the yield from leather hides and decorative fabrics used tocover the furniture needs to be optimized.

The popularity of leather is due to its durability, look and feel.Leather hides are also an expensive alternative, usually representing 2to 4 times the cost of woven goods. Therefore, maximum yield andutilization of the leather hide is essential in controlling themanufacturing cost of products containing leather. This is quitedifficult considering the irregularities of the leather hides which varyin both size and shape. Leather is also a natural product containingimperfections that must be taken into consideration when deciding whereto cut certain parts for a product.

Both manual and mechanical methods currently exist for the cutting ofleather hides while attempting to maximize leather yield.

Typical manual methods include the placement of hard (plastic orcardboard) templates on the leather hide. The leather is then typicallymarked with chalk, grease pencil, or other writing instruments using thetemplate as a guide. After the entire hide is marked, the leather isthen cut using a variety of knives, both powered and non-powered.Alternatively, sometimes the marking of the leather is omitted and theleather is cut using a non-powered rolling knife guided by following theedge of each template. Using these manual methods does not produceoptimum leather yield since the manual marker or cutter generally doesnot attempt to place the templates in very many positions before markingor cutting. Typically, there are millions of feasible placement optionsfor each template on a given leather hide and it is too time consumingto attempt placement at every possible location. It is also impossibleto know if the placement of the templates at any given locationrepresents the best yield for that particular leather hide.

Typical mechanical methods include the placement of the leather hide ona table or conveyor belt, which is part of an automated cutting machine.A person using one of two methods then defines imperfections in theleather hide. In some cases the leather hides are marked with a coloredtape, chalk or grease pencil. Each color represents a different type ofimperfection.

Often, markings on the leather hide are difficult or impossible toremove. The glue on pinstripe tape may leave residue on the hide and candamage the appearance of the surface. In other cases, the leather hideis marked digitally using a laser pointer, sonic digitizer or adigitizing tablet underneath the cutting surface on the machine. Afterdefect marking, the leather hide is photographed with a camera. Acomputer then processes the digitized image and the boundary orperimeter of the hide is determined and represented digitally by aclosed polyline. The imperfections are also processed at the same timeresulting in digital map of the imperfections and their relationship tothe boundary of the leather hide. A computer uses the digitally definedleather hide data to try multiple, iterations of digital templateplacement, taking into consideration imperfection types and locations.This is generally accomplished using various available software systemsdesigned for nesting templates on leather hides. Nesting is usuallyperformed for a specified length of time, for a specified number ofiterations, or until a yield threshold has been met or exceeded. Oncethe nesting is complete, the digital template definitions and locationsare converted to a numeric code format that is interpreted by the mastercontrol computer on the cutting machine. The machine using this digitaldata then cuts the leather hide.

While mechanical leather cutting systems of this type represent the bestavailable method for achieving improved leather yields, they are quiteexpensive and costly to maintain. In addition, leather cutting machinesdo not represent a significant labor savings and their cost must bejustified primarily on leather yield improvements alone.

With regards to decorative fabrics used to cover furniture, some of thesame drawbacks apply to the methods of cutting patterns. With fabrics,fully automated pattern optimization and cutting systems are currentlyavailable. However, these automated systems are expensive and costly tomaintain.

SUMMARY

The present subject matter provides systems and methods for increasingyield and decreasing labor in processing coverings for consumerproducts. The methods and systems utilize pairs of coordinatetransformation tables to correct images captured by a camera and thoseto be displayed by a projector. The methods and systems then use virtualmarkings projected on the system work table to define defects andcutting lines. For example, once the covering is placed on the worktable, the operator can use a pointing device to move a cursor projectedby a coordinate-corrected projector to define any imperfections on thecovering using virtual markings. Alternatively, the operator can outlinethe imperfections using a visible light or infra-red (IR) pen whoseposition is tracked by a video camera. An image of the covering may thenbe taken and, after processing to correct for camera distortions, may beused to define the boundaries of the covering. Nesting of templates forcutting or marking patterns can then be performed by a computer takinginto account the cover boundaries and the location of the virtual defectmarkings. Lines defining each template's boundary can then be projectedon the covering for the operator to use to mark or cut the templates.

It is an object of the presently disclosed subject matter to providesystems and methods for increasing yield in the processing of coveringsfor consumer products. An object of the presently disclosed subjectmatter having been stated hereinabove, and which is achieved in whole orin part by the presently disclosed subject matter, other objects willbecome evident as the description proceeds when taken in connection withthe accompanying drawings as best described hereinbelow.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter includingthe best mode thereof to one of ordinary skill in the art is set forthmore particularly in the remainder of the specification, includingreference to the accompanying figures, in which:

FIG. 1 illustrates a perspective view of an embodiment of a system thatcan be used in the processing of coverings, such as leather hides andfabrics, according to the present subject matter;

FIG. 2 illustrates a perspective view of the embodiment of the systemshown in FIG. 1 with a leather hide on a worktable of the system;

FIG. 3 illustrates a schematic view of an embodiment of a system thatcan be used to increase yield in the processing of coverings, such asleather hides, according to the present subject matter;

FIG. 4 illustrates a schematic view of an embodiment of a system shownin FIG. 3 with a projector of the system projecting an image;

FIG. 5 illustrates a perspective view of a portion of the embodiment ofthe system shown in FIG. 1;

FIG. 6A illustrates a perspective view of a portion of the embodiment ofthe system shown in FIG. 1;

FIG. 6B illustrates a perspective view of a portion of the embodiment ofthe system shown in FIG. 1;

FIG. 7 illustrates a perspective view of an embodiment of a coordinatecalibration chart that can be used in conjunction with a system that canbe used in the processing of coverings, such as leather hides andfabrics, according to the present subject matter;

FIG. 8 illustrates a perspective view of an embodiment of the systemshown in FIG. 1 in use according to the present subject matter;

FIG. 9 illustrates a perspective view of a portion of a leather hidewith virtual markings displayed thereon in an embodiment of a systemthat can be used in the processing of coverings, such as leather hidesand fabrics, according to the present subject matter;

FIG. 9A illustrates a perspective view of an embodiment of a pointingdevice that can be used in creating virtual markings according to thepresent subject matter;

FIG. 10A illustrates a perspective view of a leather hide with virtualmarkings displayed thereon in an embodiment of a system that can be usedin the processing of coverings, such as leather hides and fabrics,according to the present subject matter;

FIG. 10B illustrates a perspective view of a leather hide with virtualmarkings displayed thereon in an embodiment of a system that can be usedin the processing of coverings, such as leather hides and fabrics,according to the present subject matter;

FIG. 11 illustrates a perspective view of a leather hide with virtualmarkings displayed thereon in an embodiment of a system that can be usedin the processing of coverings, such as leather hides and fabrics,according to the present subject matter;

FIG. 12 illustrates a perspective view of another embodiment of a systemthat can be used in the processing of coverings, such as fabrics,according to the present subject matter;

FIG. 13 illustrates a perspective view of the embodiment of the systemshown in FIG. 12;

FIG. 14 illustrates a perspective view of a portion of the a rack frameof the embodiment of the system shown in FIG. 12; and

FIG. 15 illustrates a perspective view of a portion of a worktable ofthe embodiment of the system shown in FIG. 12 with a fabric thereon.

DETAILED DESCRIPTION

Reference will now be made in detail to the description of the presentsubject matter, one or more examples of which are shown in the figures.Each example is provided to explain the subject matter and not as alimitation. In fact features illustrated or described as part of oneembodiment can be used in another embodiment to yield still a furtherembodiment. It is intended that the present subject matter cover suchmodifications and variations.

Known subject” as used herein means an object or item, including, butnot limited to, maps or patterns, that have features having knowndimensional shapes and sizes and known distances between such featuresthat can be used to determine distortions and imperfections in shape,scale and locations in images taken by, for example, a camera orprojected by a projector.

“Calibration chart” as used herein means a sheet article having apattern thereon with the pattern having features, including, but notlimited to geometric shapes, having measured and known dimensions and/orhaving measured and known distances between such features. A calibrationchart can be used as a known subject to determine distortions andimperfections in images taken by a camera or projected by a projector.

“Virtual markings” as used herein means computer generated lines andfigures displayable on an output of a computer, the lines and figuresincluding but not limited to, lines drawn with a pointing device such asa mouse, templates, patterns, or the like. The virtual markings can becreated and displayed in an image projected onto an object or coverings,such as a leather hide or a fabric.

“Coverings” as used herein means generally flat, drapable articlesand/or material used to upholster furniture or cover other similarproducts. Coverings can include but are not limited to leather hides orsheet articles, such as woven fabrics, knitted fabrics, nonwovenfabrics, films or the like.

“Coordinate transformation table” or “coordinate transformationalgorithm” as used herein means a table or set of equations used toadjust the coordinates of objects in images captured by an imagingdevice or coordinates of objects in images projected by a projector toobtain their true locations and dimensions on the surface of the systemwork table and display them without distortion on the work tablesurface. The coordinate transformation table or algorithm can be createdby a comparison of the dimensions of the known subject to the dimensionsof an image of the known subject captured by an imaging device and/orprojected by a projector.

“Imaging device” as used herein means any device that is used to captureimages. Imaging devices can include, but are not limited to imagecapture devices such as cameras, digital cameras, video cameras, or thelike.

The present subject matter includes systems and methods for processingcoverings used in furniture and other products. These systems andmethods can use camera images and projected virtual markings to increasethe yield of panels cut from coverings such as leather hides, wovenfabrics, knitted fabrics, nonwoven fabrics, and the like and can reducelabor costs associated with the processing and creation of such panels.

Generally, a system for processing coverings can be provided that caninclude a worktable having a surface on which a covering is placeable.The system can also include an imaging device positioned for capturingthe image of a covering on the worktable. The imaging device can beconfigured to obtain an image of the covering on the surface of theworktable. The system can also include a projector for projecting imageson the worktable. The projector can be configured to project an imageonto the surface of the worktable and the covering on the surface of theworktable. The system can also include a pointing, device such as alight pen, IR pen, or the like which can be imaged by the imagingdevice. The system also can include a controller in communication withthe imaging device and projector. The controller can be configured totrack the movements of the pointing device such as a light pen or IR penin the images taken by the imaging device. The controller can beconfigured to correct images taken by the imaging device of the lightpen location, the surface of the worktable and the covering thereon. Thecontroller can also be configured to correct the images projected ontothe surface of the worktable and the covering thereon. Further, thecontroller can be configured to permit the showing of virtual markingson the covering placed on the surface of the worktable through an imageprojected thereon by the projector.

The controller can also be configured to utilize information provided byadditional pointing devices such as a computer mouse to create thevirtual markings that can be projected as an image from the projectoronto a covering on the surface of the worktable.

The controller can be configured to correct images taken by the imagingdevice of the surface of the worktable and the covering and any featuresprojected thereon so that the image taken is compensated to take intoaccount imperfections of the image taking process to maximize thedimensional accuracy of the corrected images. Additionally, thecontroller can be configured to correct images projected by theprojector on the surface of the worktable and the covering thereon sothat the image projected is compensated to take into accountimperfections of the image projecting process to maximize thedimensional accuracy of the corrected projected images.

More particularly, the controller can be configured to correct theimages from the camera by a process that includes a process of taking animage of, a known subject having known dimensional features by thecamera and comparing the known dimensional features of the known subjectto the dimensional features of the image to be corrected. For example,the known subject can be a calibration chart. The controller can beconfigured to correct the images taken by the camera through the use ofa first coordinate transformation table created by the comparison of thedimensions of the known subject to the dimensions of the captured image.Further, the to controller can be configured to correct the imagesprojected from the projector by a process that includes projecting animage of a known subject having known dimensional features. An image ofthe projected image can be taken with the imaging device and the knowndimensional features of the known subject can be compared to thedimensional features of the projected image to be corrected. Thecontroller can also be configured to correct the images projected by theprojector through the use of a second coordinate transformation tablecreated by the comparison of the dimensions of the known subject to thedimensions of the image of the projected image.

The controller used in the subject matter described herein for virtuallymarking a covering can be implemented using a computer readable mediumhaving stored thereon executable instructions that when executed by theprocessor of a computer control the processor to perform steps.Exemplary computer readable media suitable for implementing the subjectmatter described herein includes disk memory devices, programmable logicdevices, and application specific integrated circuits. In oneimplementation, the computer readable medium may comprise a memoryaccessible by a processor. The memory may comprise instructionsexecutable by the processor for implementing any of the methods forcorrecting images captured by an imaging device, correcting imagesprojected by a projector, tracking the movements of pointing devicessuch as a light pen or IR pen in the images taken by an imaging device,or any of the other steps described above or hereinbelow. In addition, acomputer readable medium that implements the subject matter describedherein may be distributed across multiple physical devices and/orcomputing platforms.

The following examples illustrate more specific embodiments of thesystems and methods of processing coverings. In particular, embodimentsthat can be used for processing animal hides and fabric are described.

Referring to FIGS. 1 and 2, the present subject matter provides asystem, generally designated 10, that employs a method for achievingimprovements in leather hide utilization and labor costs. The system 10can be used to process leather to optimize leather yield. In particular,the system 10 can provide improved yield, time, and labor costs in thecutting of patterns from leather hides. The system 10 can include aworktable 20, an imaging device 12, an image projector 14 and acontroller 30.

The worktable 20 can include a center top on which an animal hide AH canbe placed. Due to the size of some animal hides, the worktable 20 can bea drop-leaf table that has one or more leafs that are foldable toprovide access to the entire animal hide AH. For example, the worktable20 can have leafs 24 that can be folded downward as shown in FIG. 1 toprovide access to the center of a large hide (not shown in FIG. 1) onthe center top 22. The leafs 24 can be extended upward to a levelposition with the center top 22 as shown in FIG. 2 to provide access tothe outer portions of the animal hide AH proximal to boundaries B of theanimal hide AH. The table top, which comprises the center top 22 and theleafs 24 of the worktable 20, can have a holding mat, for example, thataids in holding the animal hide AH in the same position on the worktable20 as work is to be perform on the animal hide AH once it is placed onthe worktable 20. Further, the worktable 20 can be set at a height Hthat is ergonomically correct for the intended workers who inspect, markand cut the animal hides AH. Another example of a means for holding thehide AH to the worktable includes a vacuum table. On such a vacuumtable, the means for holding the hide AH can be a vacuum surface of thevacuum table.

The imaging device 12 is used to capture images of objects or coveringsplaced on the worktable 20, such as the animal hide AH. The imagingdevice 12 can be a camera. For example, the camera can be astill-photographic or video camera. The camera can provide a digitalimage or can provide an image that can be digitized. For example, theimaging device 12 can be a digital camera. Hereinbelow, the imagingdevice 12 will be referred to as camera 12. The camera 12 can be placedat a distance D₁ that permits the camera 12 to obtain the image, i.e.,photograph, of the entire animal hide AH during use of the system 10.

The image projector 14 is used to project an image back onto theworktable 20. The image projector 14 can be a video projector, such as adigital video projector. The image projector 14 can be positioned at adistance D₂ from the center of the worktable 20. The distance D₂ can besuch that it permits the projector 14 to display an image of any animalhide that is dimensionally the same as that actual animal hide AH thatis placed on the worktable. The distance D₂ can vary depending on thearrangement of the projector 14. As shown in FIGS. 3 and 4, for example,the projector 14 can be positioned at an angle α as measured from acentral axis A of the projector to a plane PL that is parallel to aplane CL that passes through the center of the worktable. The angle αcan be chosen based on the ability of the projector 14 to project adesired image size that can be corrected as will be explained below.

The projector 14 can be set in other arrangements as long as theprojector has the ability to display a desired image, for example, animage that corresponds dimensionally to an object, such as an animalhide resting on the worktable 20. For example, the projector 14 can beplaced at a central location above the center of the worktable 20proximal to the camera 12 so that it projects the image downwardly aboutperpendicular to the center top 22 of the worktable 20. In suchembodiments, a device that both captures images and projects them can beused. In other arrangements, one or more mirrors can be used to reflectthe image from the projector onto the worktable 20. In such embodiments,the projector can be turned toward or away from the worktable 20. Theuse of mirrors can allow for the placement of the projector closer tothe worktable when the system 10 is used in a place that may be confinedin space. In a similar manner, one or more mirrors can be used toreflect the image from the worktable 20 to the imaging device 12 whencapturing an image. Thus, the imaging device 12 can be placed in avariety of positions as well. Additionally multiple projectors may beused to improve the resolution and brightness of the projected markings.Thus, one or more projectors can be used at the same or differentlocations.

Both the camera 12 and the projector 14 can be secured in their desiredpositions relative the worktable 20 by a frame 16 as shown in FIGS. 1,2, 5, 6A and 6B. The frame 16 can be of any structure that holds thecamera 12 and the projector 14 in their desired positions relative theworktable 20 and do not interfere with the operation of the camera 12and projector 14. Ideally, the frame 16 should provide minimalobtrusiveness to the covering “marking” and cutting operations. In theembodiment shown, the frame 16 includes vertically extending beams 16A,16B on either side of the worktable 20. The beams 16A, 16B can be at adistance from the table 20 so that the beams 16A, 16B do not interferewith the associated work. For example, for worktables 20 that fold ontwo sides, the beams can be position on the non-folding sides. The beams16A, 16B can have bases 16D that provide stability to the frame 16. Theframe 16 can have a crossbar 16C that extends between the beams 16A,10B.

The crossbar 16C can have one or more instrumentation bars 18 that aresecured thereto. The instrumentation bars 18 can hold the camera 12 andthe projector 14 in their desired positions in the system 10. In theembodiment shown in FIGS. 1 and 2, the instrumentation bar 18 can holdthe camera 12 above the center of the worktable 20 and the projector 14at the desired angle and distance from the center of the worktable 20.In the embodiment shown in FIGS. 1, 2, 5, 6A and 6B, the camera 12 canbe located on an end 18A of the instrumentation bar 18 above theworktable 20 and the projector 14 can be located at an end 18B. Thecamera 12 can be held in position by a bracket 18C and the projectorheld in its angled position by a casing 18D. As noted above, otherconfigurations of the frame and/or instrumentation bar are contemplated.

The camera 12 and the projector 14 can be in communication with thecontroller 30. The controller 30 can include a computer device 32 suchas a PLC, a microcomputer, a personal computer, or the like. Further,the controller 30 can include one or more pointing devices 34, such awired or wireless mouse, light pen, or IR pen, that can be used inelectronically marking the covering, such as animal hides AH on thecomputer device 32 as will be explained in more detail below. Thecontroller 30 can be used to control the operation of camera 12 andprojector 14. For example, the controller 30 can be in wired or wirelesscommunication with the camera 12 and the projector 14. The computer 32can include software for controlling the camera 12 and projector 14,correcting the images taken by the camera 12 and the images projected bythe projector 14, and for electronically marking the hides and nestingthe desired templates to optimize the yield of leather from the animalhide AH as will be explained in more detail below.

To insure the accuracy of the system 10 in marking and cutting, forexample, an animal hide AH, the imaging device 12 and image projector 14can be calibrated or corrected. To accomplish this, the digital camera12 can capture an image of a known subject that has features thereonthat have known shapes, sizes, locations, scale and/or dimensions.

For example, the known subject can be a calibration chart 40 as shown inFIG. 7 that comprises a sheet article 42 that has a pattern of features44 thereon. The sheet article 42 can comprise paper, fabric, plastic orvinyl film, metal, wood, or the like. The features 44 on the sheetarticles can have measured and known dimensions. Further, the features44 can have measured and known distances between the features 44. Thefeatures 44 can be, for example, geometric shapes. The geometric shapescan be circles, squares, triangles, rectangles, trapezoids,nonsymmetrical shapes, or the like. As shown in FIG. 7, the geometricshapes can be circles 46. The circles 46 can have a known diameter D_(F)with known distances D_(B) between the circles 46. The calibration chart40 can be spread across the worktable 20 of system 10 as shown in FIG.8. The calibration chart 40 with its pattern of features 44 can coverthe area A_(C) that will be imaged by the camera 12 as shown in FIG. 3.For example, the calibration chart 40 with its pattern of features 44can cover the entire area that will be imaged by the camera 12. Thecamera 12 can then capture the image of the work table 12. As notedabove, while the calibration chart 40 is used to described thecorrection process, other known subjects can be used.

Using the computer 32 of the controller 30, the captured image is usedto build a coordinate transformation table by comparing the dimensionsof the camera image and the actual dimensions of the known subject. Thecamera image includes imperfections that can be caused by imperfectionsin the table surface, camera alignment, inherent errors in the camera 12and the lens of the camera 12. The coordinate transformation table isthen used to correct any image taken by the camera 12 by compensatingfor these imperfections. The computer 32 uses a program to makeadjustments to the image to bring it in dimensional alignment withfeatures 44 of the calibration chart 40.

Similarly, a projector 14 has imperfections in its alignment andinherent errors in the projector 14 and the lens of the projector 14. Tocorrect these imperfections, the same or another known image of a knownsubject, such as calibration chart 40 is projected onto the tablesurface TS as shown in FIG. 4. The digital camera 12 then captures animage of the projected image including the projector imperfections andalignment imperfections. A second coordinate transformation table isthen generated to correct the image of the projector by comparing thedimensions of the projected images based on a corrected image taken bythe camera and the dimensions of the known subject. The new correctedprojector image is then projected onto the table.

These corrections insure that the images taken by the camera 12 and usedby the controller 30 are accurate and provide accurate dimensionalinformation about the actual objects in the image. These correctionsalso insure the image projected by the projector 14 is displayedcorrectly onto the table. For example, the object of the corrected imageprojected by the projector 14 can have the same dimensions as the actualobject, such as the animal hide AH, on the worktable 20.

As stated above, the system 10 can include a worktable 20, a digitalcamera 12, a digital video projector 14, and a controller 30 thatincludes one or more pointing devices 34, a computer 32, and thenecessary associated software. Typical use of the system 10 would be asfollows. A leather hide AH can be placed on the worktable 20 with thedigital camera 12 and video projector 14 mounted overhead. Thisworktable 20 may have a large single surface or may be a multipledrop-leaf table, such as a double drop-leaf table that will enable theoperator or operators an opportunity to look closely at or even feel thesurface of the leather hide AH. If using a double drop-leaf worksurface, the operator or operators start with both drop leaf sectionsdown. The hide AH is placed on the center section 22 of the worksurface. The operator or operators will then use the pointing device 34and a video projector 14 to define the imperfections on this section ofthe hide AH.

For example, the computer 32 can run appropriate programs that permitthe pointing device 34 to act as a virtual marker. The computer projectsthe virtual markings drawn by the pointing device 34 through theprojector taking into account the necessary corrections. Using thepointing device 34 and the projector 14, the user draws around defectson the hide AH as if drawing lines on a computer screen. The computer 32collects the hide imperfection definition information from the pointingdevice 34 and displays this information by projecting an image that hasbeen corrected using the video projector coordinate transformationtable, for example, the second coordinate transformation table asreferred to herein, as shown in FIG. 9. For the system to work properly,projected images must be corrected so hide imperfection definitions willbe displayed accurately with respect to shape, scale, and location. Thecomputer display menus or other inputs may be used to select the currenttype of imperfection being defined. By using this video projected defectmap, only virtual markings, such as drawn lines 50, 52, 54, i.e.,markings shown through the projected image, are placed on the leatherhide surface and different types of defects can be represented by color,unique hatch marks, or other methods. For example, virtual markings 50may designate one defect type in the hide AH, while the virtual markings52 and the virtual markings 54 may represent different defect types.

FIG. 9A illustrates an example of an embodiment of a pointing device 34.The pointing device 34 in FIG. 9A is a light pen 34A. The light pen 34Acan comprise a light-emitting device 36, such as a light-emitting diode,that can be located, for example at a tip. However, the light-emittingdevice 36 can be at other locations on the light pen 34A. In particular,the light pen 34A can also include a switching mechanism, such as pushbutton 38, that can be used to turn power on and off to thelight-emitting device 36 at the tip of pen 34A. For example, the lightpen 34A can be battery operated and the push button 38 can turn thelight-emitting device 36 on and off.

The controller 32 shown in FIGS. 1 and 2 can be configured to track themovements of the light pen 34A (shown in FIG. 9A) in the images taken bythe imaging device 12. In particular, the imaging device 12 can, be, forexample, a video camera that can capture multiple images as thelight-emitting device 36 of the light pen 34A is turn on and emits lightthat is captured in the images as the light pen 34A and thelight-emitting device 36 are moved around the covering such as hide AH.The controller 32 tracks the movement of the light pen 34A in the imagescaptured by the imaging device 12 to record virtual markings VM. Thevirtual markings VM can be projected as an image by the projector ontothe hide AH as shown in FIG. 9A. The controller 32 can be configured tocorrect images taken by the imaging device 12 of the location of thelight pen 34A, the surface of the worktable 20 and the covering, in theform of hide AH, thereon.

The virtual markings projected on the hide are for user feedback to seewhere the operator or operators have marked or are marking the defectsto be stored in the computer. As the user draws virtual markings on thehide, the movement of the pointing devices when engaged is stored in thecomputer. This information is corrected for projection of the visualvirtual markings on the hide for user feedback.

Once the user has completed the definition of the portion of the hide AHon the center section 22 of the worktable 20, the drop-leafs are raisedand the remaining imperfections are defined. Once all imperfections aredefined, the operator can take a digital image using the camera 12. Theimage file can then be corrected using the camera coordinatetransformation table, for example, the first coordinate transformationtable as referred to herein. This corrected camera image can then beused by the software on computer 32 to collect and define boundaryinformation, such as the edges of the hide AH as well as any holes inthe hide. AH. The collected boundary information along with the markedimperfections that have been identified by the operator or operators onthe hide are then projected onto the table. Before projecting, theprojected image is corrected using the video projector coordinatetransformation table, for example, the second coordinate transformationtable as referred to herein. All of the digital data containing both theboundary B and imperfection data 50, 52, 54 can be recorded in a digitalfile on the computer. The computer 32 and a nesting algorithm can beused to verify and record the area and the quality definition of thehide. This data can be used to compare the area and quality of the hideagainst the leather vendor's calculations. The boundary B andimperfection data 50, 52, 54 can either be saved for later retrieval orused immediately.

If used immediately, the operator can request virtual markings in theform of projected template outlines 60, 62, 64 (see FIG. 10A) stored inthe computer 32 or provided to the computer 32 of the parts to be placedon the hide AH to be displayed. The operator at their discretion mayplace any of these projected templates 60, 62, 64 on the hide AH throughthe computer 32 projecting the corrected image from the projector 14onto the hide AH. A software-nesting program run on computer 32 can thenprocess the hide boundary, imperfections, and any number of templates.Iterations of template layouts 68 can be performed by the computer 32until a yield threshold is met or exceeded or until a predetermined timeor number of iterations is reached. After successful nesting of thetemplates 60, 62, 64 is complete, a corrected image containing theleather hide boundary 66, the imperfections 56, and the templateoutlines 60, 62, 64 can be projected onto the hide AH as shown in FIGS.10A and 10B. FIG. 10B shows the templates 60, 62, and 64 withinformation identifying each template 60, 62, 64, displayed in the imageto help recognize which templates 60, 62, 64 are displayed and to givethe operator a chance to confirm the layout 68 of the templates withrespect to the matching of the pieces of leather. Such information canbe taken into account by the computer 32 and the associated software,but a user can be given the opportunity to reject the layout 68 of thetemplates if deemed appropriate.

In some embodiments, the system 10 can include the ability to manuallynest at least a portion of the templates. This is especially useful onanimal hides AH where a panel is used on the cushions or other frontface portion of a piece of upholstered furniture. The same holds truefor coverings such as fabrics were a print or woven pattern would bepreferred on a cushion or other front face portion of a piece ofupholstered furniture. The template to be placed manually can beselected by the operator with a mouse or other pointing device andpositioned and rotated to the desired location on the covering such as ahide AH or fabric. Once all the templates to be placed manually areproperly positioned, the computer 32 and a nesting algorithm can nestthe rest of the templates around the manually placed templates tooptimize yield.

Once the corrected image with any projected features such as thenecessary virtual markings is projected, the user can either cut theleather pieces from the hide AH with a powered or non-powered knife 70or mark them on the hide with a pen by following the projected templateoutlines 60 as shown in FIG. 11.

The worktable 20 could be part of an automated cutting machine. In thiscase, the controller can process computerized nested image of the hideAH to drive the automated cutting machine. If the cutting machine wasequipped with two worktables 20 and associated camera 12 and projector14 for each, the operators could process a second hide while the cuttingmachine cuts the first hide.

Alternatively, the leather hide AH can be removed from the table and thedigitized image of the leather hide with marked imperfections saved forlater use. At a later time or at a different worktable or location, thedigitized image of leather hide with marked imperfections could beretrieved, nested with the templates, and projected onto another similarcutting table or the cutting surface of an automated cutting machine. Anautomated cutting machine operator would place this pre-defect detectedhide on the machine-cutting surface. A corrected digital camera 12 wouldthen capture an image of the hide boundary and calculate the best fitagainst the previous nested hide boundary of the same hide. A correctedprojector 14 would display a corrected image of the original hideboundary 66, all imperfections 50, 52, 54, and the templates 60, 63, 64to be cut out of the hide on the machine-cutting surface. The operatorcould then massage the hide boundary to the edge of the nested hideimage if necessary and start the cutting machine.

FIGS. 12-15 illustrate an embodiment of systems and methods forprocessing fabrics or other sheet material that have been manufacturedin roll form. Since fabrics and other materials are manufactured in rollform, the same type of system can be made on a moveable mount that cantravel up and down the length of a long cutting table. The system canwork in a similar manner to the leather processing system 10 with oneexception. Since the nested templates for fabric are rectilinear (likethe fabric itself), each time the camera is moved, a different portionof the nested templates can be displayed. To accomplish this, theworktable itself can use registration marks such as binary dots so thatthe system can determine where the current projector position is inrelation to the fabric and worktable and in turn be able to project thecorrect portion of the nested templates.

Referring to FIGS. 12 and 13, a system, generally designated 80, thatemploys a method for achieving improvements in covering utilization andlabor costs is provided. For example, the system 80 can be used to aidin the cutting of fabric. The system 80 has similar components to thesystem 10 described above in reference to FIGS. 1 and 2. The system 80can include a worktable 90, an imaging device 82, an image projector 84and a controller 100 (shown schematically).

The work table 92 can include one or more roll mounts 92 for housingrolls R of fabrics F. The roll mounts 92 allow the fabric F to be pulledfrom the roll R and laid on the worktable for processing and cutting.The roll mounts 92 can be attached to the worktable 90 or can be aseparate structure. The fabric f can be pulled from the roll R. Guides(not shown) can be provided under or over which the fabric F can be runto align the fabric with the top 94 of the worktable 90. Due to therectilinear nature of the fabric being packaged in roll form, theworktable 90 can be long. For example, the worktable 90 can be longerthan the worktable 20. By having a longer worktable 90, more fabric canbe processed along the worktable with each laying of the fabric F.

A rolling rack frame 86 can be provided and mounted to the worktable 90with the imaging device 82 and a projector 84 mounted to the rack frame86. In this manner, both the imaging device 82 and the projector 84 canbe secured in their desired height and angle positions above theworktable 90 by the rack frame 86 as shown in FIGS. 12-14. The rackframe 86 can include wheels, or rollers, 88 or some other movementmechanism thereon that allow the rack frame 86 to move up and down theworktable 90 in the directions FW and BW for processing the fabric F.The rollers 88 can run along a track (not shown) to keep that rollers 88in position. The rack frame 86 can be any structure that can be movedalong the worktable 90 and can hold the camera 82 and the projector 84in their desired positions relative to the worktable 90 withoutinterference with the operation of the camera 82 and projector 84.Ideally, the frame 86 should provide minimal obtrusiveness to the fabricmarking and cutting operations. For example, in the embodiment shown,the rack frame 86 provides easy access over the roller bars 86A of theframe 86 to the worktable 90. The location of the imaging device 82 andprojector 84 on the frame 86 can vary. In the embodiment shown in FIGS.12-14, the camera 82 can be located at central portion of an end 86B ofthe rack frame 86 above the worktable 90 and the projector 84 can belocated on a side portion of the end 86B. The imaging device 82 can beheld in position by a bracket 86C and the projector 84 can be held inposition by a casing 86D. As noted above, other configurations of theframe and/or positioning of the imaging device and projector arecontemplated.

As stated above in order to move the rack frame 86 with the imagingdevice 82 and projector 84 thereon, registration marks 96, such asbinary dots, can be used so that the system 80 can determine where thecurrent projector position is in relation to the fabric and worktableand in turn be able to project the correct portion of the nestedtemplates as shown in FIG. 15. At various points along the length of thecutting table, registration marks, or location marks, 96 can be placedon the top surface 94 of the worktable 90 for the purpose of positionlocation by the system 80. For example, the registration marks 96 can beat a location on the worktable 90 that is between the track T on whichthe rollers 88 of the rack frame 86 run and the position on the topsurface 94 of the worktable 90 where the fabric F resides. In thismanner, the nested templates (not shown) can be virtually projected ontothe fabric F, which can have a fabric pattern P thereon, and themovement of the rack frame 86 and the imaging device 82 and projector 84can be taken into account.

When processing roll goods, such as fabrics, predetermined positionsalong the worktable can be used to determine where the current projectorposition is in relation to the fabric and worktable. For example,detents can be placed in the tracks to hold the rack frame 86 in eachpredetermined position. These detents can operate as registration marks.By using predetermined positions, the creation of the coordinatetransformation tables for captured images and projected images for thelong table can be collected in sections. For example, the camera can bemoved to a predetermined position. The image taken at that position isused to create the first coordinate transformation table for thatposition. Additionally, the projector can be corrected at thesepredetermined positions by creating a second coordinate transformationtable for each of these positions.

The imaging device 82 and projector 84 can be the same as the imagingdevice 12 and projector 14 that are used in the system 10 to processanimal hides. Thus, the imaging device 82 and projector 84 will only bebriefly described. The imaging device 82 is used to capture images ofobjects or coverings placed on the worktable 90, such as the fabrics F.The imaging device 82 can be a camera. For example, the camera can be astill-photographic or video camera. The camera can provide a digitalimage or can provide an image that can be digitized. For example, theimaging device 82 can be a digital camera. The imaging device 82 can beplaced at a distance D₃ that permits the imaging device 82 to obtain theimage, i.e., photograph, of a portion of the fabric F on the worktable90 during use of the system 80. In particular, the image to be obtainedby the imaging device 82 can extend from side 90A to side 90A of theworktable 90, but not necessarily from end 90B to end 90B.

The image projector 84 is used to project an image back onto theworktable 90. The image projector 84 can be a video projector, such as adigital video projector. The image projector 84 can be positioned at adistance D₄ from the center of the worktable 90. The distance D₄ can besuch that it permits the projector 84 to display an image of the fabricF that is dimensionally the same as that portion of the fabric F in theimage that is taken by the imaging device 82. The distance D₄ can varydepending on the arrangement of the projector 84. As stated above,imaging device 82 and image projector 84 can be a different position onthe rack frame 86. Further, a device that both takes images and projectsthem can be used.

The camera 82 and the projector 84 can be in communication with thecontroller 100 (shown in schematic form in FIGS. 12 and 13) in the sameor similar manner as described above in reference to system 10. Thecontroller 100 can include a computer device such as a PLC, amicrocomputer, a personal computer, or the like. Further, the controller100 can include one or more pointing devices, as described above, such awired or wireless mouse, that can be used in electronically marking thefabric F in a manner that is the same or similar to that explained abovewith reference to system 10. The controller 100 can be used to controlthe operation of camera 82 and projector 84. For example, the controller100 can be in wired or wireless communication with the camera 82 and theprojector 84. The controller 100 can include software for controllingthe camera 82 and projector 84, correcting the images taken by thecamera 82 and the images projected by the projector 84, and forelectronically marking the fabric and nesting the desired templates tooptimize the yield of the fabric in a manner similar to that explainedabove with reference to system 10 and as will be explained in moredetail below. For example, the electronic marking can occur by using asoftware program on the controller 100 that uses a coordinate system tomark the boundaries of the fabric F in a corrected digital image of thefabric F and the movement of the pointing device(s) relative to thoseboundaries and saving that information for future use.

To insure the accuracy of the system 80 in marking and cutting, forexample, a fabric F, the imaging device 82 and image projector 84 can becalibrated or corrected in that same manner as described above withrespect to system 10. Therefore, the calibration and correctionprocedures will not be described again with reference to thisembodiment.

The system 80 can be used to process fabrics F by virtually marking thefabric for cutting. The system 80 can be use as follows. After layingthe fabric F out on the worktable 90, the operator can start at one endof the worktable 90 with the rolling rack frame 86 positioned so that anend of the fabric F is positioned in the active area of the system 80.After activating the system 80 for a new job, the system 80 can capturean image of the fabric F in the active area of the system 80. This imagecan then be processed so the position of the rolling rack frame 86 inrelation to the worktable 90 is known. The system can be used onexpensive matched fabrics, for example.

More expensive furniture often uses fabric that must be matched whenapplied. The most complicated matching is required with floral patterns.Examples of matching are (1) a stripe that starts at the lower back of asofa and continues up the back, over the top, down the seat back, acrossthe seat, and down the front to the bottom; (2) each cushion has aflower centered thereon; or (3) trees or animals that are larger than asingle piece of fabric in the furniture and which appear to flow acrosstwo or more pieces.

Matched fabric is typically manufactured by weaving, knitting, orprinting. Unfortunately, as fabric is manufactured, it must pass overmany rollers. As a result of the manufacturing process, fabric typicallyhas skew (i.e., the yarn going from one edge to the other across thefabric is not perpendicular to the length of the fabric) or bow (i.e.,the yarn is not straight) or both. Moreover, with printed fabric, thefabric is typically printed with a printing cylinder or by screenprinting. With either method of printing, the repeat of the pattern isnot consistent. Even if the repeat was originally perfect, the fabricstretches as it is processed. Accordingly, the manufactured fabrictypically differs considerably from the ideal in terms of skew, bow andrepeat. The fabric may also have other defects including but not limitedto dropped threads, holes, and printing defects. Because of these manydefects, matched fabric cannot be stacked with any reliability ofpattern match and therefore must be cut one layer at time.

The controller 100 can store a library of template patterns, each ofwhich comprises a number of nested templates for a particular item offurniture. The proper template pattern for the fabric to be nested canbe obtained and displayed on a display screen. The image of the fabriccan be superimposed on the template pattern. The operator can effectmovement of the displayed nested templates relative to one another andrelative to the displayed image of the fabric in order to individuallyalign the displayed templates to the displayed image of the fabric. Inperforming this individual alignment, the operator can pan from onesection of the fabric to another and can zoom (magnify or reduce) asection of the fabric. The image device 82 can pan or zoom so that theimage of the fabric moves along with the superimposed template images.The zooming or panning of the image device 82 can take place by movingthe image device 82. If the image device 82 is a stationary camera,zooming and panning can take place by manipulating the stored digitalimage.

The system 80 provides flexible on-screen manipulation of the nestedtemplates for the fabric on the controller 100. In particular, anindividual template can be translated relative to the remainingtemplates and the fabric image to provide fabric match. An individualtemplate may also be rotated relative to the other templates and thefabric. An individual template may also be skewed or bowed to take intoaccount nonlinear variations in the fabric. Accordingly, each templatemay be individually nested to provide optimal alignment with the actualfabric, notwithstanding skew, bow, repeat errors, dropped threads, holesor other imperfections and defects.

The operator can define the location of any defects in the active areaof the system 80 using the same virtual marking technique used on theleather hides AH in the system 10. The operator can also select with thepointing device the matchpoint of the fabric F. A fabric matchpoint issimply the exact location of the desired pattern center. This fabricmatchpoint can be, for example, the center of a flower, center of astripe, or the center of a plaid that is printed on or woven or knittedinto the fabric F. After defect definition is complete for the firstsection of the fabric F, the rolling rack frame 86 can then be manuallypushed to the next section of the fabric F and the process would berepeated. Alternatively, the rolling rack frame 86 can be motorized sothat it can be moved automatically or through initiation by theoperator. After the full length of the fabric F on the worktable 90 hasbeen processed, the controller 100 will nest the templates for maximumfabric yield. This nesting will take into account the previously defineddefects as well as the vertical and horizontal distance between thematchpoints.

After the nesting is complete, the templates can be projected onto thefabric F by the image projector 84 as virtual markings. The system 80can project the portion of the nested templates necessary for anyposition of the rolling rack frame 86 along the length of the worktable90. Each time the rolling rack frame 86 is moved to a different area ofthe worktable 90, an image is captured and processed to determine thecurrent location of rack frame 86 in relation to the worktable 90 andonly that portion of the nested templates is displayed. For eachposition along the worktable 90, the operator will cut along theprojected template lines eliminating the need to manually mark aroundphysical templates and thereby saving labor cost.

Thus, according to the present subject matter, systems and methods areprovided for increasing yield and decreasing labor in processingcoverings for consumer products. The methods and systems can utilize apair of coordinate transformation tables, used to correct imagescaptured by a digital imaging device and then displayed by a videoprojector. The methods and systems then use virtual markings, to definedefects and cutting lines. For example, once the covering is placed onthe table of the system, the operator or operators can then use apointing device projected by a coordinate transformation table-correctedvideo projector to define any imperfections on the covering usingvirtual markings. Nesting of templates for cutting patterns can then beperformed with the cutting lines defined by virtual markings projectedon the covering. Using the corrected image, the computer can place,rotate, bow and skew each template and project the results by correctingeach portion of the image with a coordinate transformation table andprojecting the results.

For example with an animal hide, a digital camera captures an image ofthe hide and corrects the image through a coordinate transformationtable. The corrected image is then corrected for display using a secondcoordinate transformation table for the video projector. The resultingimage, which includes the hide boundary, is then projected onto theleather hide. The resulting digital hide boundary and imperfection datais then combined with templates and nesting software to generate anoptimized nest. This optimized nest of templates is converted into animage, which is corrected through the video projector coordinatetransformation table and then projected back onto the hide as virtualmarkings. The operator then cuts the hide using a powered or non-poweredknife following the projected template outlines. An automated cuttingmachine equipped with a corrected camera and projector can use this datato cut. Similar methods and systems can be used for fabrics as outlinedabove.

Embodiments of the present disclosure shown in the Figures and describedabove are exemplary of numerous embodiments that can be made within thescope of the present subject matter. It is contemplated that theconfigurations of the systems and methods for covering processing andcutting can comprise numerous configurations other than thosespecifically disclosed. The scope of the present subject matter in thisdisclosure should be interpreted broadly.

What is claimed is:
 1. A system for processing coverings, the systemcomprising: a surface on which a covering is placeable; an imagingdevice configured to obtain an image of the covering projected on thesurface; a projector configured to project an image onto the surface andthe covering on the surface; and a controller in communication with theimaging device and projector, the controller configured to correctimages taken by the imaging device and configured to correct the imagesprojected by the projector.
 2. The system according to claim 1, whereinthe controller further comprises one or more pointing devices incommunication with the controller configured to create virtual markingsthat are projectable as part of the image from the projector onto thesurface and the covering on the surface.
 3. The system according toclaim 1, wherein the controller is configured to correct images taken bythe imaging device of the surface and the covering thereon so that theimage taken is compensated to take into account imperfections of theimage taking process to increase the dimensional accuracy of thecorrected images.
 4. The system according to claim 3, wherein thecontroller is configured to correct images projected by the projectoronto the surface and the covering thereon so that the image projected iscompensated to take into account imperfections of the image projectingprocess to increase the dimensional accuracy of the corrected images. 5.The system according to claim 1, wherein the controller is configured tocorrect images projected by the projector onto the surface and thecovering thereon so that the image projected is compensated to take intoaccount imperfections of the image projecting process to increase thedimensional accuracy of the corrected images.
 6. The system according toclaim 1, wherein the controller is configured to correct the images fromthe imaging device by a process that includes taking an image of a knownsubject having known dimensional features by the imaging device andcomparing the known dimensional features of the known subject to thedimensional features of the image to be corrected.
 7. The systemaccording to claim 6, wherein the known subject is a calibration chart.8. The system according to claim 6, wherein the controller is configuredto correct the images taken by the imaging device through the use of afirst coordinate transformation table.
 9. The system according to claim1, wherein the controller is configured to correct the images projectedfrom the projector by projecting an image of a known subject with theprojector then capturing an image of the projected image with theimaging device, correcting the captured image to account for theimperfections in the imaging device, and comparing the known dimensionalfeatures of the known subject to the dimensional features of thecorrected captured image of the projected image to be corrected.
 10. Thesystem according to claim 9, wherein the controller is configured tocorrect the images projected by the projector through the use of asecond coordinate transformation table.
 11. A method for processingcoverings comprising: placing a covering on a surface; projecting animage of the covering onto the covering by a projector; correcting theimage projected by the projector so that the corrected image that isprojected has increased dimensionally accuracy; and registering virtualmarkings through a controller that records boundary lines andimperfections on the covering.
 12. The method according to claim 11,further comprising creating a first coordinate transformation table bytaking an image of a known subject having known dimensional featureswith an imaging device and comparing the known dimensional features ofthe known subject to the dimensional features of the image of the knownsubject to identify the differences and capturing the image of thecovering and correcting the captured image of the covering using thefirst coordinate transformation table before the captured image isprojected.
 13. The method according to claim 12, further comprisingcreating a second coordinate transformation table by projecting an imageof a known subject having known dimensional features onto the surfacewith the projector, then capturing an image of the projected image withthe imaging device, correcting the captured image to account for theimperfections in the imaging device, and comparing the known dimensionalfeatures of the known subject to the dimensional features of thecorrected captured image of the projected image of the known subject toidentify the differences.
 14. The method according to claim 11, whereinthe virtual markings are projectable as part of the image from theprojector onto the surface and the covering on the surface.
 15. Themethod according to claim 14, wherein the virtual markings furthercomprise templates that are used to mark the covering into panels forcutting.
 16. The method according to claim 15, further comprisingnesting the templates taking into consideration the definedimperfections using the controller to increase optimization of yield ofthe covering.
 17. The method according to claim 16, further comprisingsending the corrected image with the virtual markings including nestedtemplates to an automated cutting machine to use in cutting thecovering.
 18. The method according to claim 11, further comprisingverifying and recording the area and the quality definition of the hidethrough the controller using the virtual markings.
 19. The methodaccording to claim 18, further comprising comparing the verified areaand quality of the hide against a leather vendor's calculations of thearea and quality using the controller.
 20. A method for correcting acaptured image to make the captured image more dimensionally accurate,the method comprising: providing a coordinate transformation table forcorrecting an image taken by a digital imaging device; capturing theimage with the digital imaging device; and correcting the captured imageusing the coordinate transformation table so that the captured image hasincreased dimensionally accuracy.
 21. The method according to claim 20,further comprising creating the coordinate transformation table bytaking an image of a known subject having known dimensional featureswith the imaging device and comparing the known dimensional features ofthe known subject to the dimensional features of the image of the knownsubject to identify the differences.
 22. A method for correcting aprojected image to make the projected image more dimensionally accurate,the method comprising: providing coordinate transformation table forcorrecting an image to be projected by a projector; projecting the imagewith the projector; and correcting the image projected by the projectorusing the coordinate transformation table so that the projected imagehas increased dimensionally accuracy.
 23. The method according to claim22, further comprising creating the coordinate transformation table byprojecting an image of a known subject having known dimensional featuresonto the surface with the projector, then capturing an image of theprojected image with the imaging device, correcting the captured imageto account for the imperfections in the imaging device, and comparingthe known dimensional features of the known subject to the dimensionalfeatures of the corrected captured image of the projected image of theknown subject to identify the differences.